Sensor mounting in an implantable blood pump

ABSTRACT

Techniques for mounting a sensor are disclosed. In some implementations, a molded interconnect device carries a sensor for transducing a position of a rotor of the implantable blood pump. The molded interconnect device includes one or more integrated electronic circuit traces configured to electrically connect the Hall sensor with a printed circuit board of the implantable blood pump, and the molded interconnect device is configured to be mounted to the printed circuit board.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No. 14/015,630, filed Aug. 30, 2013, which application claims the benefit of U.S. Provisional Application No. 61/695,624, filed Aug. 31, 2012, the full benefit of which are incorporated herein in their entirety for all purposes.

The description relates to United States Published Application No. 2012/0046514, filed Aug. 18, 2011, and titled “Implantable Blood Pump,” the entire contents of which are incorporated herein by reference.

FIELD

This description relates to mounting a sensor in a device, for example, mounting a Hall sensor in an implantable blood pump.

BACKGROUND

Ventricular assist devices, known as VADs, are implantable blood pumps used for both short-term and long-term applications where a patient's heart is incapable of providing adequate circulation. For example, a patient suffering from heart failure may use a VAD while awaiting a heart transplant. In another example, a patient may use a VAD while recovering from heart surgery. Thus, a VAD can supplement a weak heart or can effectively replace the natural heart's function. VADs can be implanted in the patient's body and powered by an electrical power source inside or outside the patient's body

BRIEF SUMMARY

The present disclosure describes one or more general aspects, implementations or embodiments involving devices, systems and methods for mounting a sensor in a device, for example, mounting a Hall sensor in an implantable blood pump.

When monitoring or controlling an electromagnetically levitated rotating object, it is useful to have sensors placed about the circumference of the rotating object to monitor its angular position, angular velocity, and any offsets from its ideal rotating axis. Placing these sensors can be challenging from the perspective of locating each sensor axially symmetric to the other sensors and facilitating an assembly process that does not impose mechanical stresses on the sensor package electrical interconnects.

One or more of the following aspects of this disclosure can be embodied alone or in combination as methods that include the corresponding operations. One or more of the following aspects of this disclosure can be implemented alone or in combination in a molded interconnect device or in an implantable blood pump that perform operations according to the one or more of the following aspects. One or more of the following aspects of this disclosure can be implemented alone or in combination in a molded interconnect device or in an implantable blood pump that includes parts according to the one or more of the following aspects.

In aspect 1, a molded interconnect device carrying a Hall sensor for transducing a position of a rotor of an implantable blood pump, the molded interconnect device is comprising: one or more integrated electronic circuit traces configured to electrically connect the Hall sensor with a printed circuit board of the implantable blood pump, wherein the molded interconnect device is configured to be mounted to the printed circuit board.

Aspect 2 according to aspect 1, wherein the molded interconnect device further comprises: at least one recess on a surface of the device, the surface being oriented towards the printed circuit board or facing the printed circuit board.

Aspect 3 according to aspect 2, wherein the recess is configured to be at least partially filled with an adhesive.

Aspect 4 according to aspect 3, wherein the adhesive is configured to mount the molded interconnect device to the printed circuit board during the operation of the pump.

Aspect 5 according to any one of aspects 2 to 4, wherein the recess is adapted to be form-fit with a soldered joint that electrically connects the printed circuit board with the one or more integrated electronic circuit traces of the molded interconnect device.

Aspect 6 according to any one of aspects 3 to 5, wherein the adhesive is applied between the Hall sensor and the printed circuit board and/or between a surface of the device and the printed circuit board.

Aspect 7 according to any one of aspects 1 to 6, wherein the molded interconnect device is configured to be attached on the printed circuit board between pole pieces of a stator of the pump.

Aspect 8 according to any one of aspects 1 to 7, wherein the Hall sensor is configured to output a voltage that is directly proportional to a strength of a magnetic field that is located in a proximity of pole pieces of a stator of the pump and the rotor of the pump.

Aspect 9 according to an implantable blood pump, the pump comprising: a housing defining an inlet opening and an outlet opening; a dividing wall within the housing defining a blood flow conduit, the blood flow conduit extending between the inlet opening and the outlet opening of the housing; a rotary motor including a stator and a rotor, the stator being disposed within the housing circumferentially about the dividing wall such that the blood flow conduit extends through the stator, the stator being disposed circumferentially about at least a part of the rotor and being positioned relative to the rotor such that in use blood flows within the blood flow conduit through the stator before reaching the rotor, and the rotor having permanent magnetic poles for magnetic levitation of the rotor; and a molded interconnect device carrying a Hall sensor, the Hall sensor being configured to transduce a position of the rotor.

Aspect 10 according to aspect 9, wherein the molded interconnect device is mounted on a printed circuit board of the rotary motor between pole pieces of the stator.

Aspect 11 according to any one of aspects 9 to 10, wherein the molded interconnect device comprises one or more integrated electronic circuit traces that are configured to electrically connect the Hall sensor with the printed circuit board.

Aspect 12, combinable with any one of aspects 1 to 11 or with any one of aspects 13 to 20, wherein the stator includes a first coil for driving the rotor and a second coil for adjusting a radial position of the rotor, the first coil and the second coil being wound around one or more of the pole pieces of the stator.

Aspect 13 according to any one of aspects 9 to 12, further comprising: at least one recess on a surface of the molded interconnect device, the surface being oriented towards the printed circuit board or facing the printed circuit board.

Aspect 14 according to aspect 13, wherein the recess is configured to be at least partially filled with an adhesive, and wherein the adhesive is adapted to secure the molded interconnect device to the printed circuit board during operation of the pump after being applied between the Hall sensor and the printed circuit board and/or after being applied between the surface of the molded interconnect device and the printed circuit board.

Aspect 15 according to any one of aspects 13 to 14, wherein the recess is adapted to be form-fit with a soldered joint that electrically connects the printed circuit board with the one or more integrated electronic circuit traces of the molded interconnect device.

Aspect 16 according to any one of aspects 9 to 15, wherein the Hall sensor is configured to output a voltage that is directly proportional to a strength of a magnetic field that is located in a proximity of the pole pieces and the rotor of the pump.

Aspect 17 according to any one of aspects 1 to 16, further comprising: an active electromagnetic control system configured to radially center the rotor within a blood flow conduit if the position transduced by the Hall sensor is outside a predefined volume within the blood flow conduit.

Aspect 18, combinable with any one of aspects 1 to 17, is a method of assembling a blood pump, the method comprising: assembling a motor stator and control electronics in a housing circumferentially about an internal dividing wall, the internal dividing wall defining the a blood flow conduit that extends from an inlet opening to an outlet opening of the housing, the stator being assembled in the housing such that the blood flow conduit extends through the motor stator; disposing a magnetically-levitated rotor within the blood flow conduit and surrounded by the stator such that impeller blades carried by the rotor are downstream of the rotor from the inlet opening, and such that, in use, the impeller pumps blood from the inlet opening to the outlet opening through the stator; mounting a molded interconnect device between pole pieces of the motor stator onto a printed circuit board of the motor stator, wherein the molded interconnect device carries a Hall sensor that is configured to transduce a position of the rotor; and electrically connecting the Hall sensor with the printed circuit board and electrically connecting the printed circuit board with the control electronics.

Aspect 19 according to aspect 18, wherein the molded interconnect device is being placed on the printed circuit board by an insertion machine.

Aspect 20 according to any one of aspects 9 to 19, wherein the molded interconnect device is in accordance with any one of the aspects 1 to 8.

In aspect 21, a sensor mount assembly comprising: a printed circuit board having rigid and flexible portions; sensors having rigid material attached thereto; and a carrier for supporting the printed circuit board and the sensors, the carrier having rails to locate the rigid material attached to the sensors.

In aspect 22, an apparatus comprising: a circuit board having an outer region, extensions, and end regions, the extensions each having a first end coupled to the outer region, the extensions each extending inward from the outer region to a second end that is coupled to one of the end regions, wherein the extensions are more flexible than the end regions; electrical interconnects disposed at the end regions; and a plurality of sensors, each of the plurality of sensors being mounted to a respective electrical interconnect disposed at one of the end regions.

Aspect 23 according to aspect 22, wherein the extensions are configured to flex to direct stress away from the end regions.

Aspect 24 according to aspect 22 or 23, wherein the outer region is more flexible than the end regions.

Aspect 25 according to any one of aspects 22 to 24, wherein the outer region is generally circular, and the extensions extend radially inward from the outer region.

Aspect 26 according to any one of aspects 22 to 25, wherein the outer region defines a closed boundary around an opening defined through the circuit board, and the extensions and end regions extend into the opening.

Aspect 27 according to any one of aspects 22 to 26, wherein the circuit board has a generally planar surface, the electrical interconnects are disposed at the generally planar surface, and the sensors extend from the generally planar surface.

Aspect 28 according to any one of aspects 22 to 27, wherein each of the extensions extends along a corresponding axis and each of the extensions has a width perpendicular to the corresponding axis; and wherein the end region located at the end of each extension has a width perpendicular to the corresponding axis of the extension, the width of the end region being greater than the width of the extension.

Aspect 29 according to any one of aspects 22 to 28, further comprising a carrier configured to attach to the circuit board and orient the sensors in a predetermined alignment with respect to a motor assembly.

Aspect 30 according to aspect 29, further comprising a plurality of guide members, each guide member being mounted to one of the sensors in the plurality of sensors; wherein the carrier is configured to attach to the circuit board and engage the guide members.

Aspect 31 according to aspect 29 or 30, wherein each of the guide members is located at an upper surface of one of the sensors in the plurality of sensors.

Aspect 32 according to any one of aspects 29 to 31, wherein each of the guide members is an electrically neutral circuit board segment.

Aspect 33 according to any one of aspects 29 to 32, wherein the carrier has an inner region that connects each of the end regions when the circuit board is received in the carrier, and the carrier has projections that extend outward from the inner region to the outer region of the circuit board when the circuit board is received in the carrier.

Aspect 34 according to any one of aspects 22 to 33, wherein the plurality of sensors comprise Hall effect sensors configured to detect magnetic fields indicative of parameters of a motor of an implantable blood pump.

Aspect 35 according to any one of aspects 22 to 34, wherein the sensors are configured to produce data indicative of a position of a rotor of an implantable blood pump.

Aspect 36 according to any one of aspects 22 to 35, wherein the sensors are configured to output a voltage that is directly proportional to a strength of a magnetic field that is located in proximity to pole pieces of a motor stator and a rotor of an implantable blood pump.

Aspect 37 according to any one of aspects 22 to 36, wherein the sensors are oriented axi-symmetrically.

In aspect 38, an implantable blood pump comprising the apparatus of any one of aspects 22 to 37.

In aspect 39, A method comprising: mounting sensors to a circuit board to form a sensor assembly; installing a mechanical carrier in a motor assembly, the mechanical carrier defining a predetermined alignment of the sensors with respect to the motor assembly; after installing the mechanical carrier in the motor assembly, placing the circuit board of the sensor assembly in the mechanical carrier; and positioning the sensors in the mechanical carrier such that the sensors are arranged in the predetermined alignment.

Aspect 40 according to aspect 39, wherein installing the mechanical carrier in the motor assembly comprises installing the mechanical carrier in a motor assembly of an implantable blood pump, the mechanical carrier defining a predetermined alignment of the sensors with respect to the motor assembly of the implantable blood pump.

Aspect 41 according to aspect 40, wherein mounting the sensors to the circuit board comprises mounting the sensors to a circuit board that has extensions that extend to end regions having electrical interconnects disposed at the end regions, the extensions being more flexible than the end regions electrically connecting the sensors to the electrical interconnects.

Aspect 42 according to aspect 41, wherein positioning the sensors in the mechanical carrier in the predetermined alignment comprises flexing the extensions of the circuit board such that the sensors are positioned in the predetermined alignment within a predetermined tolerance.

Aspect 43 according to aspect 42, wherein flexing the extensions comprises flexing the extensions to a greater degree than the end regions having the electrical interconnects.

Aspect 44 according to any one of aspects 39 to 43, wherein positioning the sensors in the carrier in the predetermined alignment comprises positioning the sensors axi-symmetrically.

Aspect 45 according to any one of aspects 39 to 44, wherein positioning the sensors in the carrier in the predetermined alignment comprises positioning the sensors in the carrier such that the sensors are located to detect one or more motor parameters of the blood pump.

Aspect 46 according to any one of aspects 39 to 45, wherein positioning the sensors in the mechanical carrier in the predetermined alignment comprises placing the sensors in the mechanical carrier such that a guide member affixed to each sensor is received in a corresponding slot defined by the mechanical carrier.

Aspect 47 according to any one of aspects 39 to 46, further comprising affixing a guide member to each sensor of the plurality of sensors.

Aspect 48 according to any one of aspects 39 to 47, further comprising, after positioning the sensors in the carrier in the predetermined alignment, removing a portion of the circuit board that extends inward beyond the sensors.

Aspect 49 according to aspect 48, wherein removing a portion of the circuit board comprises breaking off a portion of an end region along a perforated or scored line across the end region.

The following general aspects may be combinable with any one of the aspects 1 to 49.

In one general aspect, an implantable blood pump includes a housing and a blood flow conduit. Within the housing, the blood pump includes a stator located about the blood flow conduit and a magnetically-levitated rotor.

In another general aspect, an implantable blood pump includes a housing defining an inlet opening and an outlet opening. Within the housing, a dividing wall defines a blood flow conduit extending between the inlet opening and the outlet opening of the housing. The blood pump has a rotary motor that includes a stator and a rotor. The stator is disposed within the housing circumferentially about the dividing wall such that the inner blood flow conduit extends through the stator.

In another general aspect, an implantable blood pump includes a puck-shaped housing having a first face defining an inlet opening, a peripheral sidewall, and a second face opposing the first face. The blood pump has an internal dividing wall defining an inner blood flow conduit extending between the inlet opening and an outlet opening of the housing. The puck-shaped housing has a thickness from the first face to the second face that is less than a width of the housing between opposing portions of the peripheral sidewall. The blood pump also has a motor having a stator and a rotor. The stator is disposed in the housing circumferentially about the blood flow conduit and includes magnetic levitation components operable to control an axial position and a radial position of the rotor. The rotor is disposed in the inner blood flow conduit and includes an impeller operable to pump blood from the inlet opening to the outlet opening through at least a portion of the magnetic levitation components of the stator.

Implementations of the above aspects may include one or more of the following features. For example, the stator is disposed circumferentially about at least a part of the rotor and is positioned relative to the rotor such that in use blood flows within the blood flow conduit through the stator before reaching the rotor. The rotor has permanent magnetic poles for magnetic levitation of the rotor. A passive magnetic control system is configured to control an axial position of the rotor relative to the stator, and an active electromagnetic control system is configured to radially center the rotor within the inner blood flow conduit. An electromagnetic control system controls at least one of a radial position and an axial position of the rotor relative to the stator, and the electromagnetic control system has control electronics located within the housing about the dividing wall.

The control electronics are located between the inlet opening and the stator. The control electronics can be configured to control the active magnetic control system. The rotor has only one magnetic moment. The stator includes a first coil for driving the rotor and a second coil for controlling a radial position of the rotor, and the first coil and the second coil are wound around a first pole piece of the stator. The housing has a first face that defines the inlet opening, a second face opposing the first face, and a peripheral wall extending from the first face to the second face. The housing includes a rounded transition from the second face to the peripheral wall. The housing defines a volute located such that in use blood flows within the blood flow conduit through the stator before reaching the volute. The volute can be located between the stator and the second face. The housing can also include a cap that includes the second face, defines at least part of the volute, and defines at least part of the outlet. The cap is engaged with the peripheral wall of the housing. The housing also includes an inlet cannula extending from the first face and in fluid communication with the inlet opening. The inlet cannula can be inserted into the patient's heart. The outlet opening is defined in the second face and/or the peripheral wall. A thickness of the housing between the first face and the second face is less than a width of the housing.

In another general aspect, a method includes inserting a puck-shaped blood pump housing into a patient's body. The blood pump is inserted such that an opening defined in a first flat face of the housing that is proximate to a stator of the blood pump faces the patient's heart. Additionally, the blood pump is inserted such that a second rounded face of the housing that is proximate to an impeller of the blood pump faces away from the patient's heart. The first face is disposed against a portion of the patient's heart such that the second face of the housing faces away from the heart of the patient. In some implementations, the method includes inserting an inlet cannula of the housing into the patient's heart.

In another general aspect, making a blood pump includes assembling a motor stator and control electronics in a puck-shaped housing circumferentially about an internal dividing wall. The internal dividing wall defines an inner blood flow conduit that extends from an inlet opening to an outlet opening of the housing. The stator is assembled in the housing such that the inner blood flow conduit extends through the motor stator. Disposed within the inner blood flow conduit is a magnetically-levitated rotor. The rotor is surrounded by the stator such that impeller blades carried by the rotor are downstream of the stator from the inlet opening. In use, the impeller pumps blood from the inlet opening to the outlet opening through the stator.

Implementations may include one or more of the following features. For example, the rotor has only one magnetic moment. The stator includes at least one first coil for driving the rotor and at least one second coil for controlling a radial position of the rotor, the at least one first coil and the at least one second coil being wound around a first pole piece of the stator. The housing includes a first face that defines the inlet opening, and further comprising engaging an end cap with a peripheral wall of the housing, the end cap including a second face, defining at least part of a volute, and defining at least part of the outlet opening. The housing includes a rounded transition from the second face to the peripheral wall. The housing further includes an inlet cannula extending from the first face and in fluid communication with the inlet opening. A thickness of the housing between the first face and the second face is less than a width of the housing.

In another general aspect, a method of pumping blood includes magnetically rotating a centrifugal pump impeller of a blood pump device to draw blood from a patient's heart through an inlet opening of a housing of the blood pump device into an inner blood flow conduit within a stator in the housing, through the inner blood flow conduit, and through an outlet opening of the housing. The method includes selectively controlling a radial position of the impeller within the inner blood flow conduit.

In another general aspect, a sensor mount assembly includes a printed circuit board having rigid and flexible portions, sensors having rigid material attached thereto, and a carrier for supporting the printed circuit board and the sensors. The carrier has rails to locate the rigid material attached to the sensors.

The details of one or more of these and other aspects, implementations or embodiments are set forth in the accompanying drawings and the description below. Other features, aims and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a blood pump in a use position implanted in a patient's body.

FIG. 2 is a cross-sectional view of the blood pump of FIG. 1.

FIG. 3 is a partial cut-away perspective view of a stator of a blood pump.

FIG. 4 is a bottom perspective view of a blood pump.

FIG. 5 is a top perspective view of the blood pump of FIG. 4.

FIG. 6 is a bottom perspective view and side perspective view of an exemplary sensor of FIG. 3.

FIG. 7 is a top perspective view and side perspective view of an exemplary sensor in bump design.

FIG. 8 is a top perspective view and side perspective view of an exemplary sensor in via design.

FIG. 9 is a top perspective view and side perspective view of an exemplary sensor in pocket design.

FIG. 10 is an illustration of an alternative embodiment of a sensor mount.

FIG. 11 is a top view of a circuit board of the sensor mount of FIG. 10.

FIG. 12 is a cross-sectional view of the circuit board of FIG. 11 along line 12-12.

FIG. 13 illustrates a break-away tab of the circuit board of FIG. 11.

FIG. 14 is a flow diagram illustrating a method of manufacturing a sensor assembly.

Reference numbers and designations in the various drawings indicate exemplary aspects, implementations or embodiments of particular features of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

This description relates to mounting a sensor, such as a Hall sensor, in an implantable blood pump.

The subject matter described in this disclosure can be implemented in particular aspects or embodiments so as to realize one or more of the following advantages.

First, a molded interconnect device may allow a Hall sensor to be positioned at an adequate position within the blood pump, while the device may be inserted into the pump with insertion machines employed for the assembly of the pump. For example, the implementations or aspects described herein allow a Hall sensor to be positioned and mounted on a printed circuit board of a stator of the pump thereby allowing the Hall sensor to transduce a position of a rotor during operation of the pump.

Second, mechanical stress on integrated electronic conductive traces of the molded interconnect device may be reduced and may thereby enhance the robustness of a connection between the device and a printed circuit board. In general, particular aspects described herein may provide improved robustness of the device carrying the Hall sensor on the board and within the pump, e.g. for halt or break off test of the motor of the pump.

Third, the molded interconnect device carrying the Hall sensor may allow adhesives to be easily employed to further enhance the stability of the Hall sensor in the pump.

Fourth, the force applied to a soldered joint between the printed circuit board and the molded interconnect device during operation of the pump may be reduced, e.g. the force may a centrifugal force, a shear force and/or a frictional force.

Other advantages of this disclosure will be apparent to those skilled in the art.

With reference to FIGS. 1, 4 and 5, a left ventricular assist blood pump 100 having a puck-shaped housing 110 is implanted in a patient's body with a first face 111 of the housing 110 positioned against the patient's heart H and a second face 113 of the housing 110 facing away from the heart H. The first face 111 of the housing 110 includes an inlet cannula 112 extending into the left ventricle LV of the heart H. The second face 113 of the housing 110 has a chamfered edge 114 to avoid irritating other tissue that may come into contact with the blood pump 100, such as the patient's diaphragm. To construct the illustrated shape of the puck-shaped housing 110 in a compact form, a stator 120 and electronics 130 of the pump 100 are positioned on the inflow side of the housing toward first face 111, and a rotor 140 of the pump 100 is positioned along the second face 113. This positioning of the stator 120, electronics 130, and rotor 140 permits the edge 114 to be chamfered along the contour of the rotor 140, as illustrated in at least FIGS. 2, 4, and 5, for example.

Referring to FIG. 2, the blood pump 100 includes a dividing wall 115 within the housing 110 defining a blood flow conduit 103. The blood flow conduit 103 extends from an inlet opening 101 of the inlet cannula 112 through the stator 120 to an outlet opening 105 defined by the housing 110. The rotor 140 is positioned within the blood flow conduit 103. The stator 120 is disposed circumferentially about a first portion 140 a of the rotor 140, for example about a permanent magnet 141. The stator 120 is also positioned relative to the rotor 140 such that, in use, blood flows within the blood flow conduit 103 through the stator 120 before reaching the rotor 140. The permanent magnet 141 has a permanent magnetic north pole N and a permanent magnetic south pole S for combined active and passive magnetic levitation of the rotor 140 and for rotation of the rotor 140. The rotor 140 also has a second portion 140 b that includes impeller blades 143. The impeller blades 143 are located within a volute 107 of the blood flow conduit such that the impeller blades 143 are located proximate to the second face 113 of the housing 110.

The puck-shaped housing 110 further includes a peripheral wall 116 that extends between the first face 111 and a removable cap 118. As illustrated, the peripheral wall 116 is formed as a hollow circular cylinder having a width W between opposing portions of the peripheral wall 116. The housing 110 also has a thickness T between the first face 111 and the second face 113 that is less than the width W. The thickness T is from about 0.5 inches to about 1.5 inches, and the width W is from about 1 inch to about 4 inches. For example, the width W can be approximately 2 inches, and the thickness T can be approximately 1 inch.

The peripheral wall 116 encloses an internal compartment 117 that surrounds the dividing wall 115 and the blood flow conduit 103, with the stator 120 and the electronics 130 disposed in the internal compartment 117 about the dividing wall 115. The removable cap 118 includes the second face 113, the chamfered edge 114, and defines the outlet opening 105. The cap 118 can be threadably engaged with the peripheral wall 116 to seal the cap 118 in engagement with the peripheral wall 116. The cap 118 includes an inner surface 118 a of the cap 118 that defines the volute 107 that is in fluid communication with the outlet opening 105.

Within the internal compartment 117, the electronics 130 are positioned adjacent to the first face 111 and the stator 120 is positioned adjacent to the electronics 130 on an opposite side of the electronics 130 from the first face 111. The electronics 130 include circuit boards 131 and various components carried on the circuit boards 131 to control the operation of the pump 100 by controlling the electrical supply to the stator 120. The housing 110 is configured to receive the circuit boards 131 within the internal compartment 117 generally parallel to the first face 111 for efficient use of the space within the internal compartment 117. The circuit boards also extend radially-inward towards the dividing wall 115 and radially-outward towards the peripheral wall 116. For example, the internal compartment 117 is generally sized no larger than necessary to accommodate the circuit boards 131, and space for heat dissipation, material expansion, potting materials, and/or other elements used in installing the circuit boards 131. Thus, the external shape of the housing 110 proximate the first face 111 generally fits the shape of the circuit boards 131 closely to provide external dimensions that are not much greater than the dimensions of the circuit boards 131.

With continued reference to FIG. 2 and with reference to FIG. 3, the stator 120 includes a back iron 121 and pole pieces 123 a-123 f arranged at intervals around the dividing wall 115. The back iron 121 extends around the dividing wall 115 and is formed as a generally flat disc of a ferromagnetic material, such as steel, in order to conduct magnetic flux. The back iron 121 is arranged beside the control electronics 130 and provides a base for the pole pieces 123 a-123 f.

Each of the pole piece 123 a-123 f is L-shaped and has a drive coil 125 for generating an electromagnetic field to rotate the rotor 140. For example, the pole piece 123 a has a first leg 124 a that contacts the back iron 121 and extends from the back iron 121 towards the second face 113. The pole piece 123 a may also have a second leg 124 b that extends from the first leg 124 a through an opening 132 of a printed circuit board 131 towards the dividing wall 115 proximate the location of the permanent magnet 141 of the rotor 140. In an aspect, each of the second legs 124 b of the pole pieces 123 a-123 f is sticking through an opening 132 of the printed circuit board 131. In an aspect, each of the first legs 124 a of the pole pieces 123 a-123 f is sticking through an opening 132 of the printed circuit board 131. In an aspect, the openings 132 of the printed circuit board are enclosing the first legs 124 a of the pole pieces 123 a-123 f.

In an aspect, at least one molded interconnect device 128 is mounted on the printed circuit board of the pump 100, e.g. the at least one molded interconnect device 128 is mounted on the printed circuit board of the stator 120. In an aspect, the molded interconnect device 128 comprises a Hall sensor 129, e.g., the molded interconnect device 128 carries the Hall sensor 129. In some implementations, a magnetic sensor other than a Hall sensor or another type of sensor may be used instead of the Hall sensor 129. For example, the molded interconnect device 128 may be mounted on the printed circuit board 131 via one or more of integrated electric circuit traces, soldered joint and adhesive. For example, the molded interconnect device 128 may be mounted to the printed circuit board 131 using an epoxy or liquid polymer crystals as the adhesive. For instance, the molded interconnect device 128 may be glued to the printed circuit board 131.

In an aspect, the epoxy is a rapid curing, fast flowing, liquid epoxy for use as capillary flow underfill on printed circuit boards, wherein when the epoxy is fully cured, it may reduce (e.g., minimize) induced stress at solder joints between the printed circuit board 131 and the molded interconnect device 128. For example, the adhesive may improve a thermal cycling performance of the printed circuit board 131, the molded interconnect device 128 and/or the soldered joints. In an aspect, the adhesive provides the functionality of an underfill between the printed circuit board 131 and the at least one molded interconnect device 128. For example, the adhesive may be applied (e.g., as underfill) between the Hall sensor 129 and the printed circuit board 131 and/or between the printed circuit board 131 and the molded interconnect device 128.

In a general aspect, the Hall sensor 129 may be configured to transduce a position of the rotor 140 of the pump 100. For example, the Hall sensor 129 may be in upright position on the printed circuit board 131. For instance, the Hall sensor 129 may be standing orthogonally on the printed circuit board 131. For example, a longest edge of the Hall sensor 129 may be aligned to possess an orthogonal component with respect to the surface of the printed circuit board 131. In a general aspect, the Hall sensor 129 may be adapted to sense a position of the rotor 140 of the pump 100. For example, the Hall sensor 129 may provide an output voltage, which is directly proportional to a strength of a magnetic field that is located in between at least one of the pole pieces 123 a-123 f and the permanent magnet 141. For example, the Hall sensor 129 may provide an output voltage, which is directly proportional to a strength of a magnetic field that is located in a proximity of at least one of the pole pieces 123 a-123 f and the rotor 140 of the pump 100. For example, the Hall sensor 129 may provide an output voltage, which is directly proportional to a strength of a magnetic field that is located in between at least one of the pole pieces 123 a-123 f and the permanent magnet 141, and wherein the output voltage is directly proportional to a current flowing in the Hall sensor 129.

In a general aspect, the Hall sensor 129 may provide an output voltage, which is directly proportional to a strength of a magnetic field that is located in between at least one of the pole pieces 123 a-123 f and the permanent magnet 141, and the output voltage may provide feedback to the control electronics 130 of the pump 100 to determine if the rotor 140 and/or the permanent magnet 141 is not at its intended position for the operation of the pump 100. For example, a position of the rotor 140 and/or the permanent magnet 141 may be adjusted, e.g. the rotor 140 or the permanent magnet 141 may be pushed or pulled towards a center of the blood flow conduit 103 or towards a center of the stator 120.

Each of the pole pieces 123 a-123 f also has a levitation coil 127 for generating an electromagnetic field to control the radial position of the rotor 140. Each of the drive coils 125 and the levitation coils 127 includes multiple windings of a conductor around the pole pieces 123 a-123 f. Particularly, each of the drive coils 125 is wound around two adjacent ones of the pole pieces 123, such as pole pieces 123 d and 123 e, and each levitation coil 127 is wound around a single pole piece. The drive coils 125 and the levitation coils 127 are wound around the first legs of the pole pieces 123, and magnetic flux generated by passing electrical current though the coils 125 and 127 during use is conducted through the first legs and the second legs of the pole pieces 123 and the back iron 121. The drive coils 125 and the levitation coils 127 of the stator 120 are arranged in opposing pairs and are controlled to drive the rotor and to radially levitate the rotor 140 by generating electromagnetic fields that interact with the permanent magnetic poles S and N of the permanent magnet 141. Because the stator 120 includes both the drive coils 125 and the levitation coils 127, only a single stator is needed to levitate the rotor 140 using only passive and active magnetic forces. The permanent magnet 141 in this configuration has only one magnetic moment and is formed from a monolithic permanent magnetic body 141. For example, the stator 120 can be controlled as discussed in U.S. Pat. No. 6,351,048, the entire contents of which are incorporated herein for all purposes by reference. The control electronics 130 and the stator 120 receive electrical power from a remote power supply via a cable 119 (FIG. 1). Further related patents, namely U.S. Pat. Nos. 5,708,346, 6,053,705, 6,100,618, 6,879,074, 7,112,903, 6,278,251, 6,278,251, 6,249,067, 6,222,290, 6,355,998 and 6,634,224, are incorporated herein for all purposes by reference in their entirety.

The rotor 140 is arranged within the housing 110 such that its permanent magnet 141 is located upstream of impeller blades in a location closer to the inlet opening 101. The permanent magnet 141 is received within the blood flow conduit 103 proximate the second legs 124 b of the pole pieces 123 to provide the passive axial centering force though interaction of the permanent magnet 141 and ferromagnetic material of the pole pieces 123. The permanent magnet 141 of the rotor 140 and the dividing wall 115 form a gap 108 between the permanent magnet 141 and the dividing wall 115 when the rotor 140 is centered within the dividing wall 115. The gap 108 may be from about 0.2 millimeters to about 2 millimeters. For example, the gap 108 is approximately 1 millimeter. The north permanent magnetic pole N and the south permanent magnetic pole S of the permanent magnet 141 provide a permanent magnetic attractive force between the rotor 140 and the stator 120 that acts as a passive axial centering force that tends to maintain the rotor 140 generally centered within the stator 120 and tends to resist the rotor 140 from moving towards the first face 111 or towards the second face 113. When the gap 108 is smaller, the magnetic attractive force between the permanent magnet 141 and the stator 120 is greater, and the gap 108 is sized to allow the permanent magnet 141 to provide the passive magnetic axial centering force having a magnitude that is adequate to limit the rotor 140 from contacting the dividing wall 115 or the inner surface 118 a of the cap 118. The rotor 140 also includes a shroud 145 that covers the ends of the impeller blades 143 facing the second face 113 that assists in directing blood flow into the volute 107. The shroud 145 and the inner surface 118 a of the cap 118 form a gap 109 between the shroud 145 and the inner surface 118 a when the rotor 140 is levitated by the stator 120. The gap 109 is from about 0.2 millimeters to about 2 millimeters. For example, the gap 109 is approximately 1 millimeter.

As blood flows through the blood flow conduit 103, blood flows through a central aperture 141 a formed through the permanent magnet 141. Blood also flows through the gap 108 between the rotor 140 and the dividing wall 115 and through the gap 109 between the shroud 145 and the inner surface 108 a of the cap 118. The exemplary gaps 108 and 109 are large enough to allow adequate blood flow to limit clot formation that may occur if the blood is allowed to become stagnant. The gaps 108 and 109 are also large enough to limit pressure forces on the blood cells such that the blood is not damaged when flowing through the pump 100. As a result of the size of the gaps 108 and 109 limiting pressure forces on the blood cells, the gaps 108 and 109 are too large to provide a meaningful hydrodynamic suspension effect. That is to say, the blood does not act as a bearing within the exemplary gaps 108 and 109, and the rotor is only magnetically-levitated. In various embodiments, the gaps 108 and 109 are sized and dimensioned so the blood flowing through the gaps forms a film that provides a hydrodynamic suspension effect. In this manner, the rotor can be suspended by magnetic forces, hydrodynamic forces, or both.

Because the exemplary rotor 140 is radially suspended by active control of the levitation coils 127 as discussed above, and because the rotor 140 is axially suspended by passive interaction of the permanent magnet 141 and the stator 120, no rotor levitation components are needed proximate the second face 113. The incorporation of all the components for rotor levitation in the stator 120 (i.e., the levitation coils 127 and the pole pieces 123) allows the cap 118 to be contoured to the shape of the impeller blades 143 and the volute 107. Additionally, incorporation of all the rotor levitation components in the stator 120 eliminates the need for electrical connectors extending from the compartment 117 to the cap 118, which allows the cap to be easily installed and/or removed and eliminates potential sources of pump failure.

In use, the drive coils 125 of the stator 120 generates electromagnetic fields through the pole pieces 123 that selectively attract and repel the magnetic north pole N and the magnetic south pole S of the rotor 140 to cause the rotor 140 to rotate within stator 120. For example, the Hall sensor 129 may sense a current position of the rotor 140 and/or the permanent magnet 141, wherein the output voltage of the Hall sensor 129 may be used to selectively attract and repel the magnetic north pole N and the magnetic south pole S of the rotor 140 to cause the rotor 140 to rotate within stator 120. As the rotor 140 rotates, the impeller blades 143 force blood into the volute 107 such that blood is forced out of the outlet opening 105. Additionally, the rotor draws blood into pump 100 through the inlet opening 101. As blood is drawn into the blood pump by rotation of the impeller blades 143 of the rotor 140, the blood flows through the inlet opening 101 and flows through the control electronics 130 and the stator 120 toward the rotor 140. Blood flows through the aperture 141 a of the permanent magnet 141 and between the impeller blades 143, the shroud 145, and the permanent magnet 141, and into the volute 107. Blood also flows around the rotor 140, through the gap 108 and through the gap 109 between the shroud 145 and the inner surface 118 a of the cap 118. The blood exits the volute 107 through the outlet opening 105.

FIG. 6 describes a bottom and side view of an exemplary molded interconnect device 128 according to an aspect described herein. The molded interconnect device 128 may carry the Hall sensor 129 on one surface of the molded interconnect device 128, wherein the Hall sensor may be electrically connected with the molded interconnect device 128 via one or more integrated electronic circuit traces 133. In an aspect, the Hall sensor 129 may be located inside the device 128 or may be partially enclosed by the device 128. The bottom of the molded interconnect device 128 is facing the bottom side of the pump 100. The top of the molded interconnect device 128 is facing the printed circuit board 131 of the pump 100. The bottom perspective of the molded interconnect device is illustrated in FIG. 6 (lower illustration). The molded interconnect device 128 may possess a cut-out 128 a, wherein film gate material may be removed. In an aspect, a thickness 128 b of walls of the molded interconnect device 128 may be adapted for the molded interconnect device 128 to be aligned on the printed circuit board 131 with an automated assembly machine, wherein the automated assembly machine may also be used to assemble the printed circuit board 131 and/or the stator 120 of the pump 100. For example, the thickness 128 b may be below 1 millimeter, preferentially about 0.7 millimeters.

In a general aspect, to make the molded interconnect device 128 more robust one or more of the followings actions are taken. An adhesive (e.g. an underfill material) is applied between the Hall sensor 129 and a surface of the molded interconnect device 128 and/or between a surface of the molded interconnect device 128 and the printed circuit board 131. This particular aspect or implementation may limit force flow through the integrated circuit traces and rather leads the forces directly through the adhesive into the printed circuit board 131. Additionally and in an example, the adhesive may be easily implemented with the printed circuit board assembly and manufacturing process. In a further aspect, the molded interconnect device 128 may be designed with recesses (e.g., pockets) that enable a form fit between the molded interconnect device 128 and soldered joints of the printed circuit board 131. In an aspect, laser parameters for structuring the molded interconnect device 128 may be optimized and a width of the integrated electronic circuit traces may be increased. In general, in blood pumps, mechanical forces may be generated due to thermal expansion and metallized traces or joints may become separated from their supporting material, wherein the metallized traces may experience a fracture during pump operation. In a general aspect, halt tests and/or break off tests of the motor were performed and rendered one or more of the following designs of the molded interconnect device 128 particularly mechanically robust during operation of the pump.

FIG. 7 describes an exemplary top and side view of a Hall sensor in a bump design according to one or more aspects of the present disclosure. The molded interconnect device 128 carries a Hall sensor 129 and includes multiple integrated electronic circuit traces 133, wherein one or more bumps 136 may be added to the traces 133. This particular aspect may reduce mechanical stress on the traces 133, e.g., by using a mechanical form fit. In an aspect, the size of the bump 136 may be below 1 millimeters, preferentially 0.73 millimeters. For example, the molded interconnect device 128 may include four bumps 136 that are located at each corner of one surface of the device 128, wherein the surface is facing the printed circuit board 131 when the device 128 is mounted on the printed circuit board 131.

FIG. 8 describes an exemplary top and side view of a Hall sensor in a via design according to one or more aspects of the present disclosure. The molded interconnect device 128 carries a Hall sensor 129 and includes one or more integrated electronic circuit traces 133, wherein one or more electrically conductive pins 134 may each include at least one via 134 a. In an example, the pins 134 may be a part of the traces 133. This particular implementation may increase a strength of the connection between the traces 133 and the molded interconnect device 128 by implementing the via 134 a that may extend through a wall of the device 128. For example, the via 134 a is a hole or a hollow channel extending through the wall of the molded interconnect device 128. For example, the pins 134 may be soldered to the printed circuit board 131 thereby electrically connecting the Hall sensor 129 with the circuit board 131.

FIG. 9 describes an exemplary top and side view of a Hall sensor in a pocket design according to one or more aspects of the present disclosure. The molded interconnect device 128 carries a Hall sensor 129 and includes one or more integrated electronic circuit traces 133, wherein one or more electrically conductive recesses 135 or pockets 135 may be located at one or more surfaces of the device 128. For example, the recess or pocket 135 may be an electrically conductive pin that is formed by a cut-out of a wall of the device 128. For instance, the recess or pocket 135 may be formed by cutting-out a fraction of a wall of the molded interconnect device 128. For instance, the fraction may be cut out at a corner of the device 128, wherein the corner is facing the printed circuit board 131 when the device 128 is mounted on the circuit board 131. In an aspect, the width 135 b of the recess 135 may be less than 1 millimeter, preferentially 0.6 millimeter. In an aspect, the length 135 a of the recess 135 may be less than 1 millimeter, preferentially 0.8 millimeter. In an aspect, the height of the recess 135 may be less than 1 millimeter. In an aspect, the molded interconnect device is wedge- or trapeze-shaped with an apex angle 128 c between 10 and 45 degrees, preferentially 25 degrees or 30 degrees.

In an aspect, the recess or pocket 135 may be form-fit with soldered joints, the soldered joints electrically and/or mechanically connecting the printed circuit board 131 with the integrated electronic circuit traces 133 of the molded interconnect device 128. For example, each recess or pocket 135 of the device 128 may at least partially enclose a soldered joint, the soldered joints electrically and/or mechanically connecting the printed circuit board 131 with the integrated electronic circuit traces 133 of the molded interconnect device 128. In an aspect, the recess or pocket 135 may be at least partially filled with an adhesive, which mounts the device 128 to the printed circuit board 131 and secures mounting of the molded interconnect device 128 to the printed circuit board 131 of the pump 100 during operation of the pump 100. The adhesive (e.g., a liquid epoxy) may be configured to perform capillary actions on the circuit board 131 and flows into the recess or pocket 135 without an additional external force applied to the adhesive. The particular implementation described herein may remove forces applied to the traces 133 and/or the soldered joints during operation of the pump 100 and may guide these forces between the device 128 and the circuit board 131 through the adhesive (e.g. underfill), wherein the forces may for example be centrifugal forces, shear forces and/or frictional forces.

The particular implementation of the pocket design described in the context of FIG. 9 may reduce mechanical stress on the traces 133 of the molded interconnect device 128 and may thereby enhance the robustness of a connection between the device 128 and the board 131. The particular implementation of the pocket design described herein may increase the stability of the integrated electronic circuit traces 133 of the molded interconnect device 128. The particular implementation of the pocket design described herein may increase the stability of the connection between the integrated electronic circuit traces 133 and the molded interconnect device 128. The particular implementation of the pocket design described herein may reduce the force applied to the integrated electronic circuit traces 133 of the molded interconnect device 128, e.g. the force may a centrifugal force, a shear force and/or a frictional force that may occur during operation of the implantable blood pump 100. The particular implementation of the pocket design described in the context of FIG. 9 may reduce the force applied to the soldered joint between the printed circuit board 131 and the molded interconnect device 128, e.g. the force may a centrifugal force, a shear force and/or a frictional force that may occur during operation of the implantable blood pump 100. In general, the particular implementations or aspects described in FIGS. 7, 8 and 9 may provide improved robustness of the device 128 on the board 131 within the pump 100, e.g. the robustness may be determined or classified by a halt or break off test of the motor of the pump 100.

In a general aspect, using silicone coating in a proximity of the molded interconnect device 128 on the printed circuit board 131 may be a buffer and may reduce mechanical stress on the device 128 and/or the Hall sensor 129.

In a general aspect, the width of the integrated electronic circuit traces 133 may be 0.2-0.25 millimeters. In an aspect, lead-free solder may be applied between the Hall sensor 129 and the molded interconnect device 128. In an aspect, the molded interconnect device 128 is directly soldered on the printed circuit board 131 of the pump 100.

Referring to FIGS. 10 and 11, another implementation of a sensor mount 200 includes a printed circuit board 202, sensors 208, and a mechanical carrier 210. FIG. 10 illustrates the sensor mount 200 assembly as it would be configured within an assembled blood pump. FIG. 11 illustrates the circuit board 202 and sensors 208 before the circuit board 202 and sensors 208 are placed in the carrier 210 during assembly of the blood pump.

The printed circuit board 202 has rigid portions 204, and also has flexible portions 206 that provide mechanical compliance between individual sensors 208 while maintaining a single set of soldered electrical interconnects between the sensors 208 and the remainder of the system. The circuit board 202 can be, for example, a rigid-flex circuit board. Because there is compliance in the flexible portions 206, mechanical positioning tolerances in the mechanical fixtures can be accommodated without placing excessive stress on the electrical interconnects.

The sensors 208 can be soldered to the circuit board 202 while the circuit board 202 is flat and unstrained. During assembly of the pump motor assembly, the circuit board 202 is positioned on top of a carrier 210, which may already be installed in the motor assembly. The carrier 210 has guide rails 212 that orient the sensors 208 soldered to the circuit board 202. When installing the sensors 208 into the carrier 210, the flexible portions 206 of the circuit board 202 flex to permit the sensors 208 to be positioned in a precise alignment within the motor assembly.

As shown in FIG. 11, the circuit board 202 is generally planar and has an outer region 220. In some implementations, the outer region 220 is generally circular or ring-shaped. The outer region 220 defines an outer perimeter 221 that bounds an opening 222 defined through the center of the circuit board 202. The opening 222 can be located and sized to admit portions of a blood flow conduit, a pump motor stator, a pump housing, and/or a rotor through the circuit board 202 in an assembled pump.

The circuit board 202 includes extensions 230 that project inward from the outer region 220 into the opening 222. Each extension 230 may extend linearly along a corresponding longitudinal axis 239, for example, in a direction radially inward from the outer region 220. In some implementations, the extensions 230 are positioned around the interior of the outer region 220 such that there are spacings or gaps 231 between the extensions 230. In an assembled pump, a portion of the motor stator, such as a pole piece, drive coil, levitation coil, or other component, may be positioned in each of the gaps 231 between extensions 230. Each extension 230 has an outer end 232 and an inner end 234. The outer ends 232 are fixed to the outer region 220, and each inner end 234 is fixed to an end region 240.

The end regions 240 are free ends, which are not attached to the rest of the circuit board 202 except at the inner ends 234 of the respective extensions 230. Each end region 240 has electrical interconnects 250 (e.g., exposed pads) disposed at the surface of the end region 240 (see FIG. 13). Each of the end regions 240 can have a sensor 208 connected electrically and mechanically to the end region 240. Circuit traces, wires, or other conductive elements (not shown) can extend along the extensions 230 to connect the electrical interconnects 250 to other circuitry of the circuit board 202 and other pump control electronics.

In some implementations, the width, W₁, of an end region 240 is greater than the width, W₂, of the extension 230. The widths W₁, W₂ can be measured perpendicular to the longitudinal axis 239 of the extension 230. In some implementations, the end regions 240 extend perpendicular to the longitudinal axis 239 of the extensions 230 beyond one or both lateral edges 236, 238 of the extensions 230.

The extensions 230 are connected through the outer region 220, but the circuit board 202 does not otherwise connect the extensions 230 to each other. Because the extensions 230 extend freely from the outer region 220 in, for example, a cantilevered fashion, each extension 230 can flex independently of the other extensions 230 to allow positioning of the sensors 208 located at the end regions 240.

The outer region 220 and the extensions 230 are more flexible than the end regions 240. The rigidity of the end regions 240 limits the risk that a connection between the sensors 208 and the electrical interconnects 250 may fail due to excessive stress or flexion on the end regions 240. When the sensors 208 are positioned with respect to the motor stator, forces on the sensors 208 cause flexion of the extensions 230 while causing less flexion in the more rigid end regions 240 where the electrical interconnects 250 are located.

The higher rigidity of the end region 240 may be achieved by using a different material or structure than is used to form the outer region 220 and extensions 230. In addition, or as an alternative, the higher rigidity of the end regions 240 may be achieved by adding a reinforcement layer or other member to the end regions 240.

Referring to FIG. 12, the outer region 220 and extensions 230 can be include a flexible dielectric material, such as a polyimide, e.g., Kapton. For example, the outer region 220 includes a flexible dielectric layer 304 formed of, for example, polyimide, located between metal layers 302 formed of, for example, copper. A polyimide film 312 or other coating may be applied to the metal layers 302. In some implementations, the metal layers 302 are exposed at an outer edge of the outer region 220 to provide electrical connectivity.

The extensions 230 include an additional flexible dielectric layer 304 a formed of, for example, polyimide, and an additional metal layer 302 a. A layer of adhesive 310 can bond the flexible dielectric layer 304 a to one of the metal layers 302. The layers of the extensions 230 can form a flexible core 320 that extends through the end regions 240. The metal layers 302, 302 a of the extensions 230 may also be covered with a polyimide film 312 or other coating. The outer region 220, which includes fewer layers than the extensions 230, can be more flexible than the extensions 230.

The flexible dielectric layers 304, 304 a may include polyimide, as discussed above. Other suitable dielectric materials include those indicated in industry standard guideline document IPC-4202. For example, the flexible dielectric layers 304, 304 a may include polyvinylfluoride (PVF), polyethylene terephthalate polyester (PET), fluorinated ethylene-propylene copolymer (FEP), polytetrafluorethylene (PTFE), aramid, polyamide-imide, epoxy, polyetherimide, polysulfone, polyethylene naphthalate (PEN), and/or thermotropic liquid crystal polymer.

The end regions 240 can be constructed of a laminate material built around the flexible core 320. For example, the end regions 240 include the flexible core 320 and rigid dielectric layers 306 located above and below the flexible core. The rigid dielectric layers 306 may be formed of, for example, an epoxy-impregnated glass laminate, such as FR-4. Various other laminates and materials may be used, including epoxy laminates including glass, cellulose, aramid fiber, and/or fiberglass, where the materials in the laminate may be woven or non-woven. Other suitable materials are indicated in industry standard guideline document IPC-4101. The end regions 240 also include metal layers 302 b located on the rigid dielectric layers 306, and solder mask layers 308 located over the metal layers 302 b.

In the example shown in FIGS. 10-13, there are eight extensions 230, and a sensor 208 is mounted at the end region 240 of each extension 230. The sensors 208 can be Hall effect sensors or other appropriate magnetic sensors. The sensors 208 can be oriented axi-symmetrically, for example, about an axis through the center of the opening 222 extending perpendicular to the circuit board 202. For example, the sensors 208 can be positioned at equal angular offsets from the nearest sensors 208 on either side, and each sensor 208 can be oriented to face toward the center of the opening 222.

As discussed above, one or more of the sensors may be Hall effect sensors configured to detect magnetic fields indicative of parameters of a motor of an implantable blood pump. The sensors can be configured to output a voltage that is directly proportional to the strength of a magnetic field that is located in proximity to pole pieces of a motor stator and/or a rotor of an implantable blood pump. In some implementations, the sensors are configured to produce data indicative of a position of a rotor of an implantable blood pump.

Referring again to FIG. 10, after the sensors 208 are mounted to the circuit board 202, the circuit board 202 and sensors 208 are placed in a mechanical carrier 210. The assembly of the circuit board 202 and sensors 208 may be inserted in the carrier 210 by moving the sensory assembly downward along an axis, for example, along arrow A, so that the circuit board rests against an upper surface of the carrier 210. The carrier 210 can be more rigid than the circuit board 202, and can be formed of, for example, plastic or metal. In some implementations, the carrier 210 is affixed to the pump housing or motor assembly prior to insertion of the circuit board 202 and sensors 208. The carrier 210 may be mechanically integral to the motor assembly.

In an assembled blood pump, the carrier 210 acts as a precision fixture and as a mechanical support for the sensors 208. During manufacturing, the sensors 208 are soldered to the circuit board 202 while the circuit board 202 is flat and unstrained. Due to the various tolerances in fabrication and soldering, there may exist some uncertainty about the exact location of the sensors 208 after attachment to the circuit board 202. During final motor assembly, the circuit board 202, with sensors 208 already attached, is placed on top of the carrier 210. The machining or fabrication of the carrier 210 can be performed more precisely than the soldering of the sensors 208. As a result, the carrier 210 can precisely orient the sensors 208 relative to each other and relative to the rest of the motor assembly.

The carrier 210 has an inner region 252 that connects each of the end regions 240 within the opening 222. The inner region 252 can be generally circular. The carrier 210 has projections 254 that extend outward from the inner region 252. The circuit board 202, with soldered sensors 208, is received in the carrier 210 with the circuit board 202 in a substantially flat orientation. Each projection 254 of the carrier 210 receives one of the extensions 230 of the circuit board 202 in a groove 255. The projections 254 are wider than the extensions 230 and extend beyond the lateral edges 236, 238 of the extensions 230. The projections 254 extend from the inner region 252 to the outer region 220 of the circuit board 202. In some implementations, the carrier 210 has an outer region that is generally circular or ring-shaped that connects the projections 254. In some implementations, the spacings or gaps 231 are defined between the projections 254. In an assembled pump, a portion of the motor stator, such as a pole piece, drive coil, levitation coil, or other component, may be positioned in the gaps 231 between the projections 254.

The carrier 210 includes features that orient the sensors 208 in a predetermined alignment or orientation with respect to each other and with respect to the pump motor assembly. Each projection 254 of the carrier 210 includes guide rails 212 that can be used to align a sensor 208. Each pair of guide rails 212 defines a space or slot 257 in which to receive a sensor 208. When the circuit board 202 and sensors 208 are positioned in the carrier 210, the guide rails 212 extend along opposite sides of the end regions 240. The guide rails 212 define slots 256 that receive guide members 214 attached to the sensors 208. When the circuit board 202 is received in the carrier 210, the slots 256 extend generally perpendicular to the longitudinal axes 239 of the corresponding extensions 230. The slots 256 also extend substantially perpendicular to the planar surface of the circuit board 202.

The sensors 208 are appropriately positioned with respect to the rest of the motor assembly when the sensors 208 are located in the slots 257 and the guide members 214 are located in the slots 256. In this alignment, the sensors 208 may be located to, for example, to detect parameters of the pump's motor.

To facilitate positioning of the sensors 208, a guide member 214 is attached to the top surface of each sensor 208. The engagement of the guide members 214 with the guide rails 212 of the carrier 210 can align the sensors 208 relative to each other and relative to the rest of the motor assembly, e.g., pole pieces, levitation coils, drive coils, and other motor stator components. The guide members 214 can be electrically neutral rigid PCB portions. Each guide member 214 extends generally perpendicular to the longitudinal axis 239 of the extension 230 to which the sensor 208 is attached. The guide member 214 extends beyond the edges of the sensor 208, in a direction perpendicular to the longitudinal axis 239 of the extension 230, to engage the slots 256 in the guide rails 212. The guide member 214 may extend to or beyond the edges of the end regions 240.

The guide members 214 allow a person or machine assembling the sensor unit to grasp the guide member 214 and thereby manipulate the attached sensor 208 without causing mechanical damage to the sensor 208. In addition, the guide members 214 can be masked with a static dissipative coating that minimizes the risk of damage to the circuitry of the sensors 208 due to electrostatic discharge (ESD).

Referring to FIGS. 11 and 13, in some implementations, the circuit board 202 is initially formed with excess portions or break-away tabs 216 as part of the end regions 240. The tabs 216 can be formed of the same material as the region where the electrical interconnects are located, for example, a material more rigid than the material that forms the extensions 230. While attached to the circuit board 202, the tabs 216 can be used to position or otherwise hold the circuit board 202. The tabs 216 can be coated with a static electricity dissipating film to protect the sensors 208 and other components during handling.

After the sensors 208 are soldered to the end regions 240, the tabs 216 may be removed (e.g., by breaking the tabs 216 off from the remainder of the end region 240), leaving a minimum amount of rigid PCB material to support the sensors 208 and resulting in an overall smaller assembly. FIG. 10 shows the circuit board 202 after the tabs 216 have been removed.

Referring to FIG. 13, the tab 216 is removed through the use of carefully positioned “break-away” scoring marks 218 and/or small slots or holes commonly called “mouse bites.”

These features provide a way of precisely locating the break-away transition and, during the break-away process, imparting minimum stress on the soldered electrical interconnects 250 joining the sensor 208 to the remaining rigid PCB portion.

Referring to FIG. 14, a method 400 for manufacturing an implantable blood pump can include mounting sensors 208 to a circuit board 202 to form a sensor assembly (402). The sensors 208 are mounted at regions of the circuit board 202, such as the end regions 240, that are more rigid than adjacent regions of the circuit board 202, such as the extensions 230. The sensors 208 can be soldered or otherwise assembled to the circuit board 202 while the circuit board 202 is in a flat configuration, separate from the carrier 210 and the rest of the pump.

A mechanical carrier 210 is installed in the pump motor assembly (404). For example, the carrier 210 may be attached to one or more other portions of a motor stator or pump housing. The carrier 210 defines a predetermined alignment for the sensors 208 to be located with respect to each other and the other components of the motor. The carrier 210 may be installed so that portions of the motor stator, such as pole pieces, drive coils, levitation coils, or other components, are positioned in gaps 231 between projections 254 of the carrier 210.

After the mechanical carrier 210 is installed in the motor assembly, the circuit board 202 of the sensor assembly is placed in the carrier 210 (406). The circuit board 202 and the attached sensors 208 are placed over the top of the carrier 210. The circuit board 202 may be seated against the carrier 210 by, for example, moving the circuit board 202 downward against an upper surface of the carrier 210. The circuit board 202 is received in the carrier 210, for example, with each projection 254 of the carrier 210 receiving one of the extensions 230 in a groove 255. The circuit board 202 may be in a generally planar orientation when located in the carrier 210.

The sensors 208 are positioned in the carrier 210 (408). The carrier 210 orients the sensors 208 so that the sensors 208 are in the predetermined alignment with respect to the motor assembly for, for example, sensing motor parameters. The individual sensors 208 are mechanically positioned between the guide rails 212 using the tabs 216 shown in FIG. 13. Placing the circuit board 202 in the carrier 210 may involve flexing the extensions 230 and/or the outer region 220 of the circuit board 202 to precisely locate the sensors 208 relative to each other and relative to the rest of the motor assembly. For example, the carrier 210 can position the sensors 208 in an arrangement for detecting magnetic fields indicative of parameters of a pump motor. In some implementations, the carrier 210 aligns the sensors 208 axi-symmetrically. To position the sensors 208 in the carrier 210, the body of the sensor 208 can be placed in one of the slots 257, and the guide members 214 can be placed in the slots 256.

In some implementations, positioning the sensors 208 includes flexing the extensions 230 of the circuit board 202 such that the sensors 208 achieve a predetermined alignment within a predetermined tolerance. During motor assembly, for example, when positioning the sensors 208, the extensions 230 can flex to a greater degree than the end regions 240 where the electrical interconnects 250 are located.

In some implementations, after the circuit board 202 and sensors 208 are installed in the carrier 210, portions of the circuit board 202 that extend inward beyond the sensors 208 are removed. For example, a portion, such as a tab 216, of one or more of the end regions 240 may be broken off along a perforated or scored line across the end region 240.

In some implementations, the method 300 includes affixing a guide member 214 to each sensor 208, for example, at a top surface or edge opposite the region where electrical contacts of the sensor 208 are located. The sensor 208 is then manipulated by grasping the guide member 214.

A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claimed invention. For example, the cap 118 can be engaged with the peripheral wall 116 using a different attachment mechanism or technique, including snap-fit engagement, adhesives, or welding. Additionally, while the cap 118 has been described as defining the outlet opening 105 and the chamfered edge 114, the outlet opening 105 and/or the chamfered edge 114 can be defined by the peripheral wall 116 or by both the peripheral wall 116 and the cap 118. Similarly, the dividing wall 115 can be formed as part of the cap 118.

Additionally, the rotor 140 can include two or more permanent magnets. The number and configuration of the pole pieces 123 can also be varied. The operation of the control electronics 130 is selected to account for the number and position of pole pieces of the stator and permanent magnets of the rotor. Also, the cap 118 can be engaged with the peripheral wall using other techniques, such as adhesives, welding, snap-fit, shrink-fit, or other technique or structure.

Similarly, the first face 111 may be formed from a separate piece of material than the peripheral wall 116 and the first face 111, including the inlet cannula 112, can be attached to the peripheral wall 116, such as by welding, after the control electronics 130 and the stator 120 have been mounted in the internal compartment 117. The shroud 145 may be omitted and optionally replaced by other flow control devices to achieve a desired pump efficiency. As another option, the control electronics 130 can be located external to the pump 100, such as in a separate housing implanted in the patient's abdomen, or external to the patient's body.

In some implementations, the dimensions of the housing 110 can be larger or smaller than those described above. Similarly, the ratio of the width W of the housing 110 to the thickness T of the housing can be different than the ratio described above. For example, the width W can be from about 1.1 to about 5 times greater than the thickness T. Additionally, the permanent magnet 141 of the rotor 140 can include two or more pairs of north and south magnetic poles. While the peripheral wall 116 and the dividing wall 115 are illustrated as cylinders having circular cross-sectional shapes, one or both can alternatively be formed having other cross-sectional shapes, such as oval, or an irregular shape. Similarly, the peripheral wall 116 can be tapered such that the housing does not have a constant width W from the first face 111 to the second face 113.

As mentioned above, in some implementations, the blood pump 100 can be used to assist a patient's heart during a transition period, such as during a recovery from illness and/or surgery or other treatment. In other implementations, the blood pump 100 can be used to partially or completely replace the function of the patient's heart on a generally permanent basis. In a particular aspect described herein, the molded interconnect device 128 carrying the Hall sensor 129 may allow to monitor the position of the rotor of the pump 100 and may thereby help to ensure a proper operating status of the implantable blood pump 100.

The preceding figures and accompanying description illustrate example processes and example devices. But example Hall sensor 129 or molded interconnect device 128 (or other components) contemplates using, implementing, or executing any suitable technique for performing these and other tasks. It will be understood that these processes and parts are for illustration purposes only and that the described or similar techniques may be performed at any appropriate time, including concurrently, individually, in parallel, and/or in combination. In addition, many of the steps or parts in these processes may take place simultaneously, concurrently, in parallel, and/or in different orders than as shown. Moreover, molded interconnect device 128 may use components with additional parts, fewer parts, and/or different parts, so long as the devices remain appropriate. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

In other words, although this disclosure has been described in terms of certain aspects, implementations, examples or generally associated methods, alterations and permutations of these aspects, implementations or methods will be apparent to those skilled in the art.

Accordingly, the above description of example aspects, implementations or embodiments do not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure. 

What is claimed is:
 1. A method comprising: mounting sensors to a circuit board to form a sensor assembly; installing a mechanical carrier in a motor assembly, the mechanical carrier defining a predetermined alignment of the sensors with respect to the motor assembly; after installing the mechanical carrier in the motor assembly, placing the circuit board of the sensor assembly in the mechanical carrier; and positioning the sensors in the mechanical carrier such that the sensors are arranged in the predetermined alignment.
 2. The method of claim 1, wherein mounting the sensors to the circuit board comprises mounting the sensors to extensions of the circuit board, wherein the extensions extend to end regions having electrical interconnects disposed at the end regions, the extensions being more flexible than the end regions electrically connecting the sensors to the electrical interconnects.
 3. The method of claim 2, wherein positioning the sensors in the mechanical carrier in the predetermined alignment comprises flexing the extensions of the circuit board such that the sensors are positioned in the predetermined alignment within a predetermined tolerance.
 4. The method of claim 3, wherein flexing the extensions comprises flexing the extensions to a greater degree than the end regions having the electrical interconnects.
 5. The method of claim 1, wherein positioning the sensors in the mechanical carrier in the predetermined alignment comprises positioning the sensors axi-symmetrically.
 6. The method of claim 1, wherein positioning the sensors in the mechanical carrier in the predetermined alignment comprises positioning the sensors in the mechanical carrier such that the sensors are located to detect one or more motor parameters of an implantable blood pump.
 7. The method of claim 1, wherein positioning the sensors in the mechanical carrier in the predetermined alignment comprises placing the sensors in the mechanical carrier such that a guide member affixed to each sensor is received in a corresponding slot defined by the mechanical carrier.
 8. The method of claim 1, further comprising affixing a guide member to each of the sensors.
 9. The method of claim 1, further comprising, after positioning the sensors in the mechanical carrier in the predetermined alignment, removing a portion of the circuit board that extends inward beyond the sensors.
 10. The method of claim 9, wherein removing a portion of the circuit board comprises breaking off a portion of an end region along a perforated or scored line across the end region.
 11. The method of claim 2, wherein the extensions extend radially inward from an outer region of the circuit board, wherein the outer region is generally circular.
 12. The method of claim 2, wherein the circuit board comprises an opening with an outer region of the circuit board defining a closed boundary around the opening, and wherein the extensions extend radially inward from the outer region.
 13. The method of claim 1, further comprising detecting magnetic fields indicative of parameters of a motor of an implantable blood pump.
 14. The method of claim 13, wherein the parameters are indicative of a position of a rotor of the implantable blood pump.
 15. The method of claim 13, wherein the parameters are indicative of an angular position or angular velocity of a rotor of the implantable blood pump.
 16. The method of claim 1, further comprising detecting a voltage outputted by the sensors, when the voltage is directly proportional to a strength of a magnetic field that is located in proximity to pole pieces of a motor stator and a rotor of an implantable blood pump.
 17. A method comprising: mounting sensors to a circuit board to form a sensor assembly; installing a mechanical carrier in a motor assembly, the mechanical carrier defining a predetermined alignment of the sensors with respect to the motor assembly; placing the circuit board of the sensor assembly in the mechanical carrier; positioning the sensors in the mechanical carrier such that the sensors are arranged in the predetermined alignment; and after positioning the sensors in the mechanical carrier in the predetermined alignment, removing a portion of the circuit board that extends inward beyond the sensors.
 18. The method of claim 17, wherein removing a portion of the circuit board comprises breaking off a portion of an end region along a perforated or scored line across the end region.
 19. The method of claim 17, wherein mounting the sensors to the circuit board comprises mounting the sensors to extensions of the circuit board, wherein the extensions extend to end regions having electrical interconnects disposed at the end regions, the extensions being more flexible than the end regions electrically connecting the sensors to the electrical interconnects.
 20. The method of claim 17, wherein positioning the sensors in the mechanical carrier in the predetermined alignment comprises positioning the sensors axi-symmetrically. 